Vaillant ecoMAX 646 Service Manual download pdf (Page 2)

2

Page

1. Introduction 3

2. Boiler Specification 4

2.1 Technical Data 4

2.2 Dimensions 5

2.3 Boiler connections 5

2.4 Function diagram 6

3. General Requirements 7

3.1 Related documents 7

3.2 Boiler location 7

3.3 Gas supply 8

3.4 Flue system 8

3.5 Air supply 10

3.6 Electricity supply 10

3.7 Guide to system requirements 10

4. Boiler installation sequence 13

4.1 General 13

4.2 Boiler delivery 13

4.3 Preparation of boiler location 14

4.4 Installing the flue system 16

4.5 Mounting the boiler 16

4.6 Connecting the flue assembly

to the boiler 17

4.7 Electrical installation 19

4.8 Controls 20

5. Commissioning 22

5.1 Preliminary electrical checks 22

5.2 Gas supply 22

5.3 Water supply 22

5.4 Filling the heating system 23

5.5 Initial system flush ('cold') 23

5.6 Initial lighting 24

5.7 Gas inlet working pressure 25

5.8 Main burner pressure 25

5.9 Adjusting central heating

output (range rating) 26

5.10 Functional checks 27

5.11 Checking flame

supervision device 28

5.12 Final system flush ('hot') 28

5.13 Fitting case 28

5.14 Handing over to user 29

Page

6. Servicing 29

6.1 Initial inspection 29

6.2 Routine maintenance 30

6.3 Re-commissioning the boiler 31

7. Parts replacement 32

7.1 Initial preparation 32

7.2 Fan 34

7.3 Air pressure switch 34

7.4 Burner 35

7.5 Electrodes 35

7.6 Temperature sensor (NTC) 36

7.7 Gas valve 36

7.8 Main Heat exchanger 37

7.9 CH expansion vessel 38

7.10 Transformer 39

7.11 Overheat thermostat 39

7.12 Pump 39

7.13 Automatic air release 40

7.14 Automatic bypass 40

7.15 Diverter valve 40

7.16 Pressure and temperature

gauge 41

7.17 Differential pressure switch 41

7.18 DHW microswitch 42

7.19 DHW heat exchanger 42

7.20 Circuit boards 43

8. Fault finding 44

8.1 Introduction 44

8.2 Logical fault finding procedure 44

8.3 Fault finding charts 45

9. Electrical diagrams 54

9.1 Functional flow diagram 54

9.2 Wiring diagram 55

9.3 Schematic appliance

circuit diagram 56

10. Short parts list 57

11. Supplementary LPG

information 59

Leave these instructions with the user

when the installation is completed.

1 2 3 4 5 6 7 ... 59 60

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